This is a repost of my last thread to keep it simple since most troubleshooting is out of the way(not all)
93 YJ 4.0 208k miles died while driving, doesn't start.
Code 42 Automatic Shutdown relay open or shorted.
Asd relay terminals have power. Ecu power and grounds check out(pins 3 and 9 to 11 and 12) but the ASD relay socket doesn't have resistance in any terminal to pin 57 of ecu. The wire coating is nonexistant in some places. It's the green wire with an orange stripe. Coating is gone in many places, bare copper. I'm about to go cut more electrical tape so I can find where it splits to the injectors and ecu to find a possible break or short.

Thanks to "Que89YJ" and everyone else for help troubleshooting. I am rather inexperienced in wiring so thanks for bearing with me.

I'm almost to the point of just getting a buddy to tow me to a mechanic who is very close to me but I think I can do it today if I have the wonderful help of jf and all this time on this Sunday.

We are almost there, I just have to find the short and replace most if not all of the wire.
The places the coating is melted? (or nonexistant none the less) are:
some after the harness that comes from the pdc, around the front of the engine and where it goes to the o2 sensor. Some places the coating is fine. there is also about 1/4 inch of it missing right before the ignition coil harness. that's what I've found but my question is where does it split to go to the injectors and back to the ecu?

I'm gonna try to take the wiring harness thing off the alternator but everything's so covered in mud(not only from me lol) and the compressor is in the way so those make visibility slim and I can't find much on removing it online.

I'm making this thread if anyone else ever has my problem because I couldn't find much online about it and I don't know enough about it to blindly tackle it on my own. Thanks for the help, I'm gonna attach pictures best I can on mobile. Sorry for the wall of text.

I believe that the dkgrn/org wire is the power feed to the ASD and the injectors that originates from the alternator.

If my guess is correct you lost power to the injectors which is their common feed...IF the power does get to the ASD relay.

 

I believe that the dkgrn/org wire is the power feed to the ASD and the injectors that originates from the alternator. If my guess is correct you lost power to the injectors which is their common feed...IF the power does get to the ASD relay.

Meter on ohms the resistance is good from pin 57 to the injectors

 

Those injectors need VOLTAGE to fire. Voltage should always be present.

They are 'fired' by their individual ground circuits.

 

Note on the last picture the two wires on the left are perfectly fine.

 

(battery is disconnected.)(meter on 200 ohms) pin 57 to the exposed wire that goes into the power distribution center reads about 7 probably because the grimy wire but from pin 57 to terminal 30 of the asd relay flashes a reading of about 125 then nothing. Could that mean a problem in the terminal?

 

30 on the ASD is the power feed to the relay.
The ground for the relay will be 85 or 86 to 57 on the ECM 57.




Relay
30 feed power
85 switched power
86 ground
87 output


***85 and 86 can be switched IE 85 ground and 86 switched power.***

 

!!

30 on the ASD is the power feed to the relay.
The ground for the relay will be 85 or 86 to 57 on the ECM 57.

Relay
30 feed power
85 switched power
86 ground
87 output

***85 and 86 can be switched IE 85 ground and 86 switched power.***

LBM, can you copy and paste the FSM section on how the ASD relay works ? That might bring an understanding to the functionality.

EDIT: I do not have that info for this year YJ, BUT I have this:

Just ignore the circuit designation until you look at the diagrams. This is for a 95YJ so, some wire colors will be different. 2.5 VS 4.0 two less of some stuff for the 2.5!

http://www.jeepforum.com/forum/f12/...m/forum/f12/my-feeble-attempt-explain-yj-starting-circuit-2702474/#post25442250

 

LBM, can you copy and paste the FSM section on how the ASD relay works ? That might bring an understanding to the functionality.

 

30 on the ASD is the power feed to the relay. The ground for the relay will be 85 or 86 to 57 on the ECM 57. Relay 30 feed power 85 switched power 86 ground 87 output ***85 and 86 can be switched IE 85 ground and 86 switched power.***

there is no reading on any asd relay terminal to pin 57 so there is a disconnect somewhere. I suspect the wire burnt through other wires too and is contacting them as well.

 

I have the alternator wiring disconnected finally. I'm not sure where to proceed except replacing the exposed wire??

 

Wire melted in a clump. Should I get an entire new wiring harness?

 

Split them all apart and tape them up real quick.
Check all fuses to se if they are all good.
Then see if it starts up. If it does then shut it down disco the + battery cable from the battery and repair any insulation or bad wiring you can find for now.
Then go on eBay and see if you can find another engine harness or any harness you need.

 

Thanks LBM

AUTOMATIC SHUT DOWN RELAY (ASD relay)
• When the ignition switch is in either the START or RUN position, it connects circuit A1 from fuse 4 in the PDC to circuit A21.
• Circuit A21 powers fuse 5 in the fuse block. Circuit G50 from the fuse 5 splices to power the coil side of the Automatic Shut Down relay.
• The PCM provides ground for the relay in circuit K51.
• Circuit K51 connects to cavity 51 of the PCM.
• Circuit A14 from fuse 1 in the PDC supplies battery voltage to the contact side of the ASD relay.

Chopped to the relay terminals
• Circuit A21 powers fuse 5 in the fuse block. Circuit G50 from the fuse 5 splices to power the coil side of the Automatic Shut Down relay. pin 85 or 86
* The PCM provides ground for the relay in circuit K51. Again it could be pin 85 or 86 to the ECM connector #51
• Circuit A14 from fuse 1 in the PDC supplies battery voltage to the contact side of the ASD relay. 30
* Pin 87 is the grn/red 12volt supply to the sensors


So we have all the terminals (pins IDed) with where they go and their function.

 

Thanks LBM

AUTOMATIC SHUT DOWN RELAY (ASD relay)
• When the ignition switch is in either the START or RUN position, it connects circuit A1 from fuse 4 in the PDC to circuit A21.
• Circuit A21 powers fuse 5 in the fuse block. Circuit G50 from the fuse 5 splices to power the coil side of the Automatic Shut Down relay.
• The PCM provides ground for the relay in circuit K51.
• Circuit K51 connects to cavity 51 of the PCM.
• Circuit A14 from fuse 1 in the PDC supplies battery voltage to the contact side of the ASD relay.

Chopped to the relay terminals
• Circuit A21 powers fuse 5 in the fuse block. Circuit G50 from the fuse 5 splices to power the coil side of the Automatic Shut Down relay. pin 85 or 86
* The PCM provides ground for the relay in circuit K51. Again it could be pin 85 or 86 to the ECM connector #51
• Circuit A14 from fuse 1 in the PDC supplies battery voltage to the contact side of the ASD relay.
* Pin 87 is the grn/red 12volt supply


So we have all the terminals (pins IDed) with where they go and their function.

It was my pleasure to help a fellow Jeep owner and Jeep Forum member.

 

You know, a new harness might not be a bad idea. Something went way wrong and burned up a lot.


The other option would be to remove the harness, buy the tools and connectors and rebuild it. It would likely cost you more this way.


Wish you were close to Darryl (Que) or myself. We could build you a harness.

 

Wires going to the alternator are fine. Does that mean it wasn't the alternator shorting? @que

 

You know, a new harness might not be a bad idea. Something went way wrong and burned up a lot. The other option would be to remove the harness, buy the tools and connectors and rebuild it. It would likely cost you more this way. Wish you were close to Darryl (Que) or myself. We could build you a harness.

where are yall located?

 

Chris at CFoffroad is an option also.
http://www.cfoffroad.com/index.html

Tell him Darryl and John sent you.

 

SE Michigan, both of us.
Don`t tell nobody but we are friends.

 

:thumbsup: I might be an a hole but I do enjoy helping folks that are willing to help themselves.

Lol, if anything has ever made me feel stupid in life it has been this wiring project. That being said I learned some and I appreciate everyone's patience. I'm debating going to my local mechanic... But if I can do it cheaper which I know I can then I might do it.

 

People who are ignorant of knowledge are not bad people. But stupid people are those that don't want to learn given the opportunity. That does not describe you.

So we'll just say that you are a 'genius in training' :rofl::rofl::rofl:

BTW where are you located? And please, fill out your profile.

 

Chopped to the relay terminals
• Circuit A21 powers fuse 5 in the fuse block. Circuit G50 from the fuse 5 splices to power the coil side of the Automatic Shut Down relay. pin 85 or 86
* The PCM provides ground for the relay in circuit K51. Again it could be pin 85 or 86 to the ECM connector #51
• Circuit A14 from fuse 1 in the PDC supplies battery voltage to the contact side of the ASD relay. 30* Pin 87 is the grn/red 12volt supply to the sensors



I missed pin 30 and changed a couple words around.




A new harness and install will be a helluva lot cheaper then taking it to the man. Pressure wash the engine compartment and start there. Cannot make it any worse, yes ?

 

The reason I'm considering just having my mechanic do it is because I have very little time for me to work on it (maybe an hour every afternoon and then more on weekends) but I need to be driving it ASAP as I don't have another vehicle.

 

Get in touch with this outfit. They may have what you want also.

www.2ndlifejeeps.com

 

The wire pictured that has bare copper showing goes to the o2 sensor. The (also)green/orange wire going to the injectors is in perfect shape! Does that mean short in o2 sensor?

Sent from my iPhone using JeepForum

 

Unplug the O2 sensor and see if it starts up.

 

The wire that's supposed to be going to the pdc.. Sent from my iPhone using JeepForum

 

That certainly isn't helping is it!?

 

Understand your situation but from all the information and pictures you have provided that harness may be beyond reasonable repair.

 

Understand your situation but from all the information and pictures you have provided that harness may be beyond reasonable repair.

how much should I expect the mechanic to quote me?

Sent from my iPhone using JeepForum

 

More then what you can get a new to you harness for.
One problem will be sourcing terminals for the various connectors. They can be found but it will take time to locate ship and rebuild what you have.
An example, I have made a new harness for my YJ that uses later years technology.....OBD2....despite connections with Chrysler factory techs for parts it was easier to change the harness layout and use GM parts and aftermarket fuse/ relay boxes. A mechinac will charge for his time and parts

 

I know it would be more but the question would be how much more, because I need a vehicle to drive and I have limited time to spend fixing it daily. My schedule is even more restricted having to borrow my mom's car to drive to workouts and such. (I'm only 16 not gonna lie)